Biosensor and method of making

ABSTRACT

An electrochemical biosensor with electrode elements that possess smooth, high-quality edges. These smooth edges define gaps between electrodes, electrode traces and contact pads. Due to the remarkable edge smoothness achieved with the present invention, the gaps can be quite small, which provides marked advantages in terms of test accuracy, speed and the number of different functionalities that can be packed into a single biosensor. Further, the present invention provides a novel biosensor production method in which entire electrode patterns for the inventive biosensors can be formed all at one, in nanoseconds—without regard to the complexity of the electrode patterns or the amount of conductive material that must be ablated to form them.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation in Part of U.S. patentapplication Ser. No. 09/840,843, filed Apr. 24, 2001; a Continuation inPart of U.S. application Ser. No. 10/264,891, filed Oct. 4, 2002; aContinuation-in-Part of U.S. application Ser. No. 10/601,144, filed Jun.20, 2003; and claims priority to U.S. patent application Ser. No.60/480,397, filed Jun. 20, 2003, each of which is hereby incorporated byreference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a method of making a biosensor, morespecifically a biosensor having electrode sets formed by laser ablation.

BACKGROUND

Electrochemical biosensors are well known and have been used todetermine the concentration of various analytes from biological samples,particularly from blood. Examples of such electrochemical biosensors aredescribed in U.S. Pat. Nos. 5,413,690; 5,762,770 and 5,798,031; and6,129,823 each of which is hereby incorporated by reference.

It is desirable for electrochemical biosensors to be able to analyzeanalytes using as small a sample as possible, and it is thereforenecessary to minimize the size of their parts, including the electrodes,as much as possible. As discussed below, screen-printing, laserscribing, and photolithography techniques have been used to formminiaturized electrodes.

Electrodes formed by screen-printing techniques are formed fromcompositions that are both electrically conductive and screen-printable.Furthermore, screen printing is a wet chemical technique that generallyallows reliable formation of structures and patterns having a gap widthor feature size of approximately 75 μm or greater. Such techniques arewell known to those of ordinary skill in the art.

Laser scribing is a technique that usually uses a high power excimerlaser, such as a krypton-fluoride excimer laser with an illuminationwavelength of 248 nm, to etch or scribe individual lines in theconductive surface material and to provide insulating gaps betweenresidual conductive material which forms electrodes and other desiredcomponents. This scribing is accomplished by moving the laser beamacross the surface to be ablated. The scribing beam generally has arelatively small, focused size and shape, which is smaller than thefeatures desired for the product, and the formation of the producttherefore requires rastering techniques. Such a technique can be rathertime consuming if a complex electrode pattern is to be formed on thesurface. Further, the precision of the resulting edge is rather limited.This scribing technique has been used to ablate metals, polymers, andbiological material. Such systems are well known to those of ordinaryskill in the art, and are described in U.S. Pat. Nos. 5,287,451,6,004,441, 6,258,229, 6,309,526, WO 00/73785, WO 00/73788, WO 01/36953,WO 01/75438, and EP 1 152 239 each of which is hereby incorporated byreference. It would be desirable to have a new method of formingelectrodes which allows precise electrode edges, a variety of featuresizes, and which can be formed in a high speed/throughput fashionwithout the use of rastering.

SUMMARY OF THE INVENTION

The present invention provides an electrochemical biosensor withelectrode elements that possess smooth, high-quality edges. These smoothedges define gaps between electrodes, electrode traces and contact pads.Due to the remarkable edge smoothness achieved with the presentinvention, the gaps can be quite small, the advantages of which aredescribed below. Further, the present invention provides a novelbiosensor production method in which entire electrode patterns for theinventive biosensors can be formed all at one, innanoseconds—irrespective of the complexity of the electrode patterns orthe amount of conductive material that must be ablated to form them.

In one form thereof, the present invention provides a biosensorcomprising a base substrate having first and second electrode elementsformed thereon. The first and second electrode elements have first andsecond respective edges defining a gap therebetween. The gap has a widthand a length. The first edge is spaced by a first distance from a first“theoretical line” that corresponds to the desired or ideal shape andlocation of the first edge. This first distance varies along the lengthof the gap because the edge actually produced is not as smooth orperfect as the desired theoretical line. The standard deviation of thefirst distance is less than about 6 μm over the entire length of thegap. The biosensor also includes a reagent at least partially coveringthe base substrate and one or more layers overlying and adhered to thebase substrate. The one or more layers cooperate to form asample-receiving chamber and a cover for the biosensor, and at least aportion of both the reagent and an electrode are positioned in thechamber.

In a related form of the inventive biosensor described above, the actualor real deviation of the edge from the theoretical line is no more thanabout 6 μm along the entire length of the gap. Stated another way, thedistance between the edge actually produced and the theoretical line (ifthe edge were perfect) is less than 6 μm no matter where along the gapthe distance is measured. More preferably, the real deviation is lessthan about 4 μm, most preferably less than about 2 μm. In this mostpreferred form, it is possible to space the electrodes as close as about5 μm without having the electrical components touch and thus short.Similarly, the width of the features of the electrical pattern such aselectrode fingers or traces can be as narrow as about 10 μm. Asdiscussed in detail below, the close spacing of electrode componentsallowed by the present invention in turn allows a greater number ofelectrode elements and thus greater functionality in a smaller area.

The smoothness or quality of the edges is most important in areas of thebiosensor where adjacent edges are positioned close to one another,e.g., the gap between two electrodes. In a preferred aspect of thepresent invention, like the first edge discussed above, the second edgeis spaced from a second theoretical line by a second distance thatvaries along the length of the gap. The first and the second theoreticallines thus define a “theoretical gap” therebetween. If the productionprocess were perfect, and if the edges were intended to be straight andparallel to one another, the theoretical gap width would be constantalong its length. In practice, however, the actual gap width varies fromthe theoretical one along the length of the gap. Deviations fromtheoretical of the first and second edges can be compounded to producelarger variations in the actual gap width than are produced in eitheredge alone. In a preferred form of the invention, the standard deviationof the second distance is less than about 6 μm over the entire length ofthe gap. More preferably, the standard deviation of both the first andsecond distances is less than about 2 μm, even more preferably, lessthan about 1 μm.

In another preferred form of the invention, the method comprisesremoving at least 10% of the conductive material, more preferably atleast 50% of the conductive material, and most preferably at least 90%of the conductive material. The conductive material is preferablyremoved by broad field laser ablation, which allows relatively largepercentages of the conductive layer to be removed from the basesubstrate very quickly to form electrode patterns. For example, inpreferred forms, the entire electrode pattern for a biosensor is formedby broad field laser ablation in less than about 0.25 seconds, morepreferably in less than about 50 nanoseconds, and most preferably inless than about 25 nanoseconds.

As noted above, the inventive method also allows for the placement oftwo or more electrode sets having different feature sizes in the samebiosensor. Furthermore, as noted above, the feature sizes can be quitesmall and spaced close together.

In another form, the present invention provides an efficient and fastmethod for mass producing biosensors having electrode patterns with thehighly desirable smooth edges discussed above. In this method, a web ofbase substrate material having a metal conductive layer formed thereonis provided. An image of an electrode pattern is projected onto themetal conductive layer with a laser apparatus such that an electrodepattern that corresponds to the image is formed by laser ablation on theweb of base substrate material. Either the laser apparatus or the web ofbase substrate material (or both) is moved and this process is repeatedto produce many electrode patterns at spaced intervals along the web ofbase substrate material. A reagent is deposited on the web of basesubstrate material and at least partially covers each electrode patternof the plurality of electrode patterns. At least one web of a coveringlayer or a spacing layer is laminated over the web of base substratematerial, thereby forming a cover and a sample-receiving cavity for eachbiosensor. The resulting laminated web of layers is then cut intoindividual biosensors.

In a preferred form, the image projected by the laser apparatus is ofthe complete electrode pattern for one of the biosensors, such that thecomplete electrode pattern for each biosensor is formed in a single stepwith a single laser image. In another preferred form, more than oneentire electrode pattern is formed all at once; i.e., the image includespatterns for two or more biosensors.

In another preferred form, the electrode pattern includes at least twoelectrode sets having different feature sizes. Examples of this mayinclude one set of electrodes for measuring analyte concentration andanother set for detecting whether and when the biosensor has received anadequate dose of sample fluid. The inventive biosensor may also includeelectrode elements providing other features, such as biosensoridentification, calibration or other information associated with thebiosensor.

One advantage of this inventive mass production process is that it ismuch faster than prior art processes that require forming electrodepatterns by screen printing, lithography, rastering and the like. Withthe laser ablation process employed by the present invention, the entireelectrode pattern for a biosensor can be formed all at once, in a singlestep, in only nanoseconds. This allows a continuous web of material fromwhich the individual biosensors will ultimately be cut to be processedat speeds of 60 meters per minute or greater.

Not only is the inventive process much faster than prior art processes,it provides biosensors with electrode patterns whose edges have muchbetter edge quality than prior art biosensors. Edge quality becomesincreasingly important as electrode spacing becomes closer. Closeelectrode spacing is desirable because it generally increases theaccuracy of the test result, reduces sample size, and yields a quickertest. Additionally, it allows a greater quantity of electrode elementsand associated functionalities to be packed into a single biosensor.

Yet another advantage of the inventive production method is that itallows a large percentage of the electrically conductive layer to beremoved from the base substrate all at once. By contrast, prior artrastering processes use a collimated laser beam that slowly scribes andremoves only a thin line of conductive material, which is a much longerand less versatile process in comparison with the present invention.

Another advantage related to the one just noted is that themanufacturing process of the present invention provides great freedom inthe shape and variation in the electrode pattern produced in theinventive biosensors. Asymmetric or anisotropic electrode patterns donot present a problem with the manufacturing process of the presentinvention. Further, since the electrode pattern is preferably projectedon the base substrate by a laser image formed by a mask, limitations asto size, shape, number of electrode patterns, gap width, etc. that areencountered with prior art processes are reduced. By comparison,rastering processes are typically limited to movement of a focused laserbeam along axes that are oriented 90 degrees relative to one another.The resulting patterns typically are limited to thin lines of the samewidth oriented parallel or perpendicular to one another. In addition,separate but adjacent conductive metal planes used to carry separatesignals in a device can capacitively couple when the separation distancebetween the planes becomes very small resulting in signal degradationand interference between the planes. A method that allows removal ofmore conductive material between isolated traces therefore can beadvantageous in minimizing such interference.

The following definitions are used throughout the specification andclaims:

As used herein, the phrase “electrically conductive material” refers toa layer made of a material that is a conductor of electricity,non-limiting examples of which include a pure metal or alloys.

As used herein, the phrase “electrically insulative material” refers toa material that is a nonconductor of electricity.

As used herein, the term “electrode” means a conductor that collects oremits electric charge and controls the movement of electrons. Anelectrode may include one or more elements attached to a commonelectrical trace and/or contact pad.

As used herein, the term “electrical component” means a constituent partof the biosensor that has electrical functionality.

As used herein, the phrase “electrode system” refers to an electricalcomponent including at least one electrode, electrical traces andcontacts that connect the element with a measuring instrument.

As used herein, the term “electrode element” refers to a constituentpart of an electrode system. Specific non-limiting examples of electrodeelements include electrodes, contact pads and electrode traces.

As used herein, the phrase “electrode set” is a grouping of at least twoelectrodes that cooperate with one another to measure the biosensorresponse.

As used herein, the term “pattern” means a design of one or moreintentionally formed gaps, a non-limiting example of which is a singlelinear gap having a constant width. Not included in the term “pattern”are natural, unintentional defects.

As used herein, the phrase “insulative pattern” means a design of one ormore intentionally formed gaps positioned within or between electricallyinsulative material(s). It is appreciated that electrically conductivematerial may form the one or more gaps.

As used herein, the phrase “conductive pattern” means a design of one ormore intentionally formed gaps positioned within or between electricallyconductive material(s). It is appreciated that exposed electricallyinsulative material may form the one or more gaps.

As used herein, the phrase “microelectrode array” means a group ofmicroelectrodes having a predominantly spherical diffusionalcharacteristic.

As used herein, the phrase “macroelectrode array” means a group ofmacroelectrodes having a predominantly radial diffusionalcharacteristic.

As used herein, the phrase “electrode pattern” means the relativeconfiguration of the intentionally formed gaps situated between theelements of electrodes in an electrode set specifically or biosensorgenerally. Non-limiting examples of “electrode patterns” include anyconfiguration of microelectrode arrays, macroelectrode arrays orcombinations thereof that are used to measure biosensor response.“Electrode pattern” may also refer to the shape and configuration of allelectrical components that are formed on the biosensor.

As used herein, the phrase “feature size” is the smallest dimension ofgaps or spaces found in a pattern. For example, in an insulativepattern, the feature size is the smallest dimension of electricallyconductive gaps found within or between the electrically insulativematerial(s). When, however, the pattern is a conductive pattern, thefeature size is the smallest dimension of electrically insulative gapsfound within or between the electrically conductive material(s).Therefore, in a conductive pattern the feature size represents theshortest distance between the corresponding edges of adjacent elements.

As used herein, the term “interlaced” means an electrode pattern whereinthe elements of the electrodes are interwoven relative to one another.In a particular embodiment, interlaced electrode patterns includeelectrodes having elements, which are interdigitated with one another.In the simplest form, interlaced elements include a first electrodehaving a pair of elements and a second electrode having a single elementreceived within the pair of elements of the first electrode.

As used herein, the term “ablating” means the removing of material. Theterm “ablating” is not intended to encompass and is distinguished fromloosening, weakening or partially removing the material.

As used herein, the phrase “broad field laser ablation” means theremoval of material from a substrate using a laser having a laser beamwith a dimension that is greater than the feature size of the formedpattern. Broad field ablation includes the use of a mask, pattern orother device intermediate a laser source and a substrate. The laser isprojected through the mask, the latter of which forms an image of anelectrode pattern which is projected onto and impinges on the substrateto create all or part of the electrode patterns on the substrate. Broadfield laser ablation simultaneously creates the pattern over asignificant area of the substrate. The use of broad field laser ablationavoids the need for rastering or other similar techniques that scribe orotherwise define the pattern by continuous movement of a relativelyfocused laser beam relative to the substrate. A non-limiting example ofa process for broad field laser ablation is described below withreference to biosensor 210.

As used herein, the term “line” means a geometric figure formed by apoint moving in a first direction along a pre-determined linear orcurved path and in a reverse direction along the same path. In thepresent context, an electrode pattern includes various elements havingedges that are defined by lines forming the perimeters of the conductivematerial. Such lines demarcating the edges have desired shapes, and itis a feature of the present invention that the smoothness of these edgesis very high compared to the desired shape.

“Theoretical line” as used herein refers to the desired or ideal shapeand location of an edge of an electrode element that would be obtainedif the manufacturing process were perfect. In most cases, if the edge isstraight, the theoretical line will coincide with the average locationof the edge.

As used herein, the term “point” means a dimensionless geometric objecthaving no properties except location.

The smoothness or quality of the edge of an electrode element can bedefined by the distance that the placement of the edge differs from thetheoretical line that represents the perfect or ideal edge. That is, theedge will be spaced from the theoretical line by a distance that variesalong the length of the edge. This distance will range from zero to amaximum value. One useful way to define the quality or smoothness of anedge is to simply specify the maximum distance that the edge is spacedfrom the theoretical line over a specified length of the edge.

The smoothness or quality of an edge can also be specified in terms ofthe “standard deviation” of the distance between the edge and thetheoretical line over a specified length of the edge. To calculate thestandard deviation, the distance must be measured at discrete intervalsalong the length, as described in further detail herein. If the varyingdistance is denoted “d” and the number of data points is denoted n, thenthe standard deviation of the distance is calculated as{Σ(d_(i))²/(n−1)}^(1/2). So that the equation just noted accuratelyapproximates the integral equation from which it is derived, theintervals at which data points are taken should be spaced closelytogether. All standard deviations expressed herein are measured bytaking data points that are spaced by no more than about 20 μm,preferably closer.

As used herein, the term “smoothness standard deviation,” when referringto an edge of an electrode element, refers to the standard deviation ofthe distance that the edge is spaced from a theoretical line over aspecified length of the edge. The quality of a gap between electrodeelements can be expressed in terms of the individual deviations orstandard deviations of the two edges forming the gap from thetheoretical lines corresponding to the two edges.

As used herein, the phrase “biological fluid” includes any bodily fluidin which the analyte can be measured, for example, interstitial fluid,dermal fluid, sweat, tears, urine, amniotic fluid, spinal fluid andblood.

As used herein, the term “blood” includes whole blood and its cell-freecomponents, namely plasma and serum.

As used herein, the term “working electrode” is an electrode at whichanalyte, or product, is electrooxidized or electroreduced with orwithout the agency of a redox mediator.

As used herein, the term “counter electrode” refers to an electrode thatis paired with the working electrode and through which passes anelectrochemical current equal in magnitude and opposite in sign to thecurrent passed through the working electrode. The term “counterelectrode” is meant to include counter electrodes, which also functionas reference electrodes (i.e., a counter/reference or auxiliaryelectrode).

As used herein, the term “electrochemical biosensor” means a deviceconfigured to detect the presence and/or measure the concentration of ananalyte by way of electrochemical oxidation and reduction reactionswithin the biosensor. These reactions are transduced to an electricalsignal that can be correlated to an amount or concentration of theanalyte.

Additional features of the invention will become apparent to thoseskilled in the art upon consideration of the following detaileddescription of the preferred embodiment exemplifying the best mode knownfor carrying out the invention. It should be understood, however, thatthe detailed description and the specific examples, while indicatingembodiments of the invention, are given by way of illustration only,since various changes and modifications within the spirit and scope ofthe invention will become apparent to those skilled in the art from thisdetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings form part of the present specification and areincluded to further demonstrate certain aspects of the presentinvention. The invention may be better understood by reference to one ormore of these drawings in combination with the detailed description ofspecific embodiments presented herein:

FIG. 1 is a perspective view of a biosensor of the present invention;

FIG. 2 is an exploded assembly view of the biosensor of FIG. 1;

FIG. 3 is an enlarged plan view of the biosensor of FIG. 1 showing amacroelectrode array and a microelectrode array;

FIG. 4 is a diagram of the deviation of an edge of an electrode elementfrom a theoretical or ideal line representing the desired shape andplacement of the edge;

FIG. 5 is a diagram of the deviation in gap width and placementresulting from the deviations in the two individual edges forming thegap;

FIG. 6 is an enlarged section of the microelectrode array of FIG. 3;

FIG. 7 is a diagram of the deviation of an edge of an electrode elementfrom a theoretical or ideal line representing the desired shape andplacement of the edge;

FIG. 8 illustrates a cross-section taken along lines 8-8 of FIG. 1;

FIG. 9 illustrates a cross-section taken along lines 9-9 of FIG. 1;

FIG. 10 is a graph showing the deviation from mean or theoretical of anelectrode edge of the microelectrode array of FIG. 3;

FIG. 11 is an exploded assembly view of a biosensor in accordance withanother embodiment of the invention;

FIG. 12 is an exploded assembly view of a biosensor in accordance withanother embodiment of the invention;

FIG. 13 is an exploded assembly view of a biosensor in accordance withanother embodiment of the invention;

FIG. 14 is an exploded assembly view of a biosensor in accordance withanother embodiment of the invention;

FIG. 15 is an exploded assembly view of a biosensor in accordance withanother embodiment of the invention;

FIG. 16 is an enlarged perspective view of a biosensor in accordancewith another embodiment of the invention;

FIG. 17 is a view of an ablation apparatus suitable for use with thepresent invention;

FIG. 18 is a view of the laser ablation apparatus of FIG. 17 showing asecond mask;

FIG. 19 is a view of an ablation apparatus suitable for use with thepresent invention;

FIG. 20 is a schematic of an electrode set ribbon of the presentinvention;

FIG. 21 is a photograph illustrating a biosensor substrate initiallycoated with a gold conductive layer from which approximately 10% of theconductive material has been removed;

FIG. 22 is a photograph illustrating a biosensor substrate having anelectrical pattern with a gap width of approximately 20 μm and whereapproximately 20% of the conductive material initially covering thesubstrate has been removed to form the electrical pattern;

FIG. 23 is a photograph illustrating a biosensor substrate having anelectrical pattern with a gap width of approximately 20 μm and whereapproximately 50% of the of a conductive material initially covering thesubstrate has been removed to form the electrical pattern; and

FIG. 24 is a photograph illustrating a biosensor substrate having anelectrical pattern with a gap width of approximately 250 μm and whereapproximately 90% of the conductive material initially covering thesubstrate has been removed to form the electrical pattern.

DETAILED DESCRIPTION OF THE INVENTION

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings, and specific language will be used to describe theembodiments. It will nevertheless be understood that no limitation ofthe scope of the invention is intended. Alterations and modifications inthe illustrated devices, and further applications of the principles ofthe invention as illustrated therein, as would normally occur to oneskilled in the art to which the invention relates are contemplated, aredesired to be protected.

A biosensor in accordance with the present invention provides a surfacewith electrode patterns formed thereon, the electrode patternspreferably having a smooth edge quality. It is a particular aspect ofthe present invention that precise quality is obtained for the edges ofthe electrical components located on the biosensor. Having a smooth orhigh edge quality of the elements can contribute to greater precision,accuracy, and reproducibility of test results. Further, a smooth or highedge quality also allows for a great number of electrode arrays to beformed on a defined surface area of the biosensor. By increasing theedge quality of the elements, it is possible to increase the number ofelectrode elements and thus increase the achievable functionality in thedefined surface area. These functions may include, for example: multiplemeasurement electrode pairs for simultaneous measurement of the same ordifferent analytes, including by alternative means; electrodes used toprovide correction factors for the basic measurement electrodes;electrodes for detecting dose application or sample sufficiency;multiple electrode traces to monitor electrode functioning or to providedetection or correction of defective traces; and multiple contact padsfor coupling to the foregoing functionalities, or for providingadditional features such as identification, calibration, or otherinformation pertaining to the biosensor. Further, the selectedfunctionalities for a given biosensor can be provided in a smaller spacewhen the high edge quality allows closer placement of the electricalcomponents. It is a feature of the present invention to enable all ofthis, and more, in a manner that is relatively fast, reliable and costeffective.

Specifically, a biosensor of the present invention has electricalcomponents with edges that are smooth and are precisely located. Theprecise locating of the smooth edge is important, particularly relativeto a corresponding edge of another electrical component, and especiallywith respect to a paired element. The importance and the degree ofquality of a component's edge quality and placement will vary with thenature of the component.

For macroelectrodes, the edge smoothness and placement are important forthe quality of the electrochemical results obtained by use of themacroelectrodes. One factor in the accuracy of such a test is thereproducibility of the area of each macroelectrode. Obtaining preciseedge smoothness and placement will yield an area which is highlyaccurate. Another factor in the use of macroelectrodes is the placementof one of the electrodes relative to the other, e.g., the position ofthe counter element(s) in relationship to the position of the workingelement(s). Moreover, since biosensors are generally operated based oncalibration methods that rely on the reproducibility of the sizes andlocations of the measuring electrodes, the ability to consistentlyproduce lots of such tests trips can enhance the results achieved withthe tests.

Similarly, the edge smoothness and placement contribute to the resultsobtained from microelectrodes. For microelectrodes, the issues can bemagnified because of the number and relatively close placement of thenumerous microelements. Poor edge quality can greatly affect theoperating characteristics of microelectrodes, and the present inventionhelps to overcome this potential problem. Moreover, an advantage ofplacing microelements in close proximity is the rapid establishment ofsteady-state operation. High edge quality and precise edge placementenables closer placement of the elements and in turn faster achievementof steady-state operation. In addition, such closer placement allows fora greater number of microelements to be placed in a given space.

In a first aspect, the present invention provides a high quality edgefor the various electrical components on a biosensor. The quality of theedge relates to the smoothness or uniformity of the edge relative to atheoretical profile of the edge. Non-limiting examples of such “smooth”edges formed in accordance with the present invention are shown in FIGS.21-24.

In one respect, the smoothness relates simply to the deviation of theedge surface relative to the theoretical line defining the desired shapeof the edge. It will be appreciated that any electrical component on abiosensor has an intended location and shape that will not be exactlyduplicated by the physical embodiment. The extent to which the actualedge of the component varies from the theoretical one is a measure ofthe smoothness of the edge. As discussed above, this smoothness orquality of the edge can be expressed in terms of the varying distancethat the edge is spaced from a theoretical line over a specified length.This distance can be measured at closely spaced intervals, as discussedin detail below, and the standard deviation of the distance can becalculated. Further, the maximum value the distance achieves over aspecified length is also a meaningful parameter. For example, in adesign where electrodes are to form a gap having a desired width of,e.g., 10 μm, the manufacturing process must be capable of producingedges that will vary by less (preferably much less) than 5 μm over thelength of the gap. Otherwise, the electrodes may touch and thus shortcircuit.

As relates to the various electrical components, the extent to which agiven portion of the component is “smooth” may vary. Referring inparticular to the measuring electrodes, it will be appreciated thatcertain edges of the elements are more critical than others. Forexample, certain edges of the counter and working electrodes areadjacent one another and spaced closely together, while others are not.Also, certain edges are located within the sample-receiving chamber, andothers are not. In a first aspect, the present invention relates toproviding smooth edges for all of the edges of the measuring electrodes.In another aspect, the invention provides smooth edges particularly forthe edges of the measuring electrodes located within thesample-receiving chamber, and more particularly for the edges of themeasuring elements that are adjacent to one another. “Adjacent edges” inthis context refers to the fact that an edge of a counter element isclosest to, i.e., adjacent to, an edge of an element of a workingelectrode with which the counter electrode is paired.

As indicated previously, the present invention relates in one aspect toproviding macroelectrodes having a closely determined area. The desiredaccuracy of the provided area can vary based on the absolute size of themacroelectrode, as determined by the quality of the edges defining theelectrode. Thus, as the smoothness of the edges improves, the differencebetween the area actually occupied by the electrode and the desired areadecreases.

The spacing of macroelectrodes also can benefit from the presentinvention. For example, for macroelectrodes that are spaced apart by 250μm, the edges forming the gap preferably have a smoothness standarddeviation of less than about 4 μm over the entire length of the edges;for elements spaced apart by 100 μm, the standard deviation ispreferably less than about 2 μm.

For microelectrodes, the desired smoothness can differ. For example, formicroelements that are spaced apart by 50 μm, the adjacent edges have asmoothness standard deviation of less than about 6 μm, preferably lessthan about 2 μm, and most preferably less than about 1 μm. If themicroelements are spaced apart by about 10 μm, then the smoothnessstandard deviation is preferably less than about 1 μm, more preferablyless than about 0.5 μm. In general, the smoothness standard deviationfor microelectrodes is preferably less than about 5% of the width of thegap between adjacent microelements (i.e., feature size), more preferablyless than about 2% of the feature size.

It is also an aspect of the present invention that the other electricalcomponents can be provided with smooth edges to facilitate closeplacement of such components. Such other components preferably have asmoothness standard deviation that is less than about 6 μm, and morepreferably less than about 2 μm.

The present invention also provides for the accurate placement of theelectrical components relative to one another and to the overallbiosensor. The relative placement of components is achieved, at least inpart, by the use of broad field laser ablation that is performed througha mask or other device that has a precise pattern for the electricalcomponents. The relative placement of the components therefore does notdepend on the controlled movement of a rastering laser or of thesubstrate relative to the rastering laser. Moreover, this accuratepositioning of adjacent edges is further enhanced by the closetolerances for the smoothness of the edges.

Therefore, in a further aspect the invention provides electricalcomponents that have gaps or features that are precisely controlled.More specifically, the electrical components will have designed,theoretical configurations for the gaps between adjacent edges, whereasthe physical embodiments will have variations and irregularities. Thepresent invention provides gaps between adjacent edges that are highlyuniform. Specifically, the present invention provides a “uniform gap,”which is defined as a gap for which the smoothness standard deviationfor each edge defining the gap is less than about 6 μm. Preferably, thesmoothness standard deviation of both edges defining the gap is lessthan about 2 μm, more preferably less than about 1 μm.

It is appreciated that the biosensor of the present invention issuitable for use in a system for assessing an analyte in a sample fluid.In addition to the biosensor, the system includes a meter (not shown)and provides methods for evaluating the sample fluid for the targetanalyte. The evaluation may range from detecting the presence of theanalyte to determining the concentration of the analyte. The analyte andthe sample fluid may be any for which the test system is appropriate.For purposes of explanation only, a preferred embodiment is described inwhich the analyte is glucose and the sample fluid is blood orinterstitial fluid. However, the present invention clearly is not solimited in scope.

Non-limiting examples of meters suitable for use with the biosensor ofthe present invention for determination of the analyte in the samplefluid are disclosed in U.S. Pat. Nos. 4,963,814; 4,999,632; 4,999,582;5,243,516; 5,352,351; 5,366,609; 5,405,511; and 5,438,271, thedisclosures of each being incorporated herein by reference. The suitablemeter (not shown) will include a connection with electrodes of thebiosensor, and circuitry to evaluate an electrochemical signalcorresponding to the concentration of the analyte. The meter may alsoinclude electrical components that determine whether the sample fluidhas been received by the biosensor and whether the amount of samplefluid is sufficient for testing. The meter typically will store anddisplay the results of the analysis, or may alternatively provide thedata to a separate device.

The biosensor of the present invention forming part of the system canprovide either a qualitative or quantitative indication for the analyte.In one embodiment, the biosensor cooperates with the meter to indicatesimply the presence of the analyte in the sample fluid. The biosensorand meter may also provide a reading of the quantity or concentration ofthe analyte in the sample fluid. In a preferred embodiment, it is afeature of the present invention that a highly accurate and precisereading of the analyte concentration is obtained.

The biosensor is useful for the determination of a wide variety ofanalytes. The biosensor, for example, is readily adapted for use withany suitable chemistry that can be used to assess the presence of theanalyte. Most preferably, the biosensor is configured and used for thetesting of an analyte in a biological fluid. Commensurate modificationsto the system will be apparent to those skilled in the art. For purposesof explanation, and in a particularly preferred embodiment, the systemis described with respect to the detection of glucose in a biologicalfluid.

The biosensor is also useful with a wide variety of sample fluids, andis preferably used for the detection of analytes in a biological fluid.In addition, the biosensor is useful in connection with reference fluidsthat are used in conventional fashion to verify the integrity of thesystem for testing.

In a preferred embodiment, the biosensor is employed for the testing ofglucose. The sample fluid in this instance may specifically include, forexample, fresh capillary blood obtained from the finger tip or approvedalternate sites (e.g., forearm, palm, upper arm, calf and thigh), freshvenous blood, and control solutions supplied with or for the system. Thefluid may be acquired and delivered to the biosensor in any fashion. Forexample, a blood sample may be obtained in conventional fashion byincising the skin, such as with a lancet, and then contacting thebiosensor with fluid that appears at the skin surface. It is an aspectof the present invention that the biosensor is useful with very smallfluid samples. It is therefore a desirable feature that only a slightincising of the skin is necessary to produce the volume of fluidrequired for the test, and the pain and other concerns with such methodcan be minimized or eliminated.

Biosensor 210 in accordance with an embodiment of the present inventionhas two electrode patterns having different feature sizes on a commonplanar surface and thus permits the accurate measurement of an analytein a fluid. As shown in FIG. 1, biosensor 210 comprises a base or basesubstrate 212, conductive material 216 positioned on the base 212, aspacer 214, and a cover 218. The cover 218 and spacer 214 cooperate withthe base 212 to define a sample-receiving chamber 220 (FIG. 9) having asample inlet opening 221 for the sample fluid, and a reagent 264 forproducing an electrochemical signal in the presence of a test analyte.The biosensor 210 is formed as a test strip, particularly one having alaminar construction providing an edge or surface opening to thesample-receiving chamber 220. The reagent 264, as shown in FIGS. 2 and9, is exposed by the sample-receiving chamber 220 to provide theelectrochemical signal to a working electrode also positioned within thechamber 220. In appropriate circumstances, such as for glucosedetection, the reagent may contain an enzyme and optionally a mediator.

The base 212 of biosensor 210 includes edges 222 that define oppositeends 224, 226 and sides 228, 230 extending between the ends 224, 226.Base 212 also has a top surface 232 supporting the conductive material216 and an opposite bottom surface 234 (FIGS. 8 and 9). Illustratively,base 212 has a length of 40 mm and a width of 10 mm. It is appreciated,however that these values are merely illustrative and that thedimensions of the base 212 may vary in accordance with the presentdisclosure.

The base 212 is a substrate that is formed from an insulating material,so that it will not provide an electrical connection between electrodesformed from the conductive material 216. Non-limiting examples ofsuitable insulating materials include glass, ceramics and polymers.Preferably, the base is a flexible polymer and has a strong absorbancein the UV. Non-limiting examples of suitable materials includepolyethylene terephthalate (PET), polyethylene naphthalate (PEN), andpolyimide films. The suitable films are commercially available asMELINEX®, KALADEX® and KAPTON®, respectively from E.I. duPont deNemours, Wilmington, Del., USA (“duPont”) and UPILEX®, a polyimide filmfrom UBE Industries Ltd, Japan. Preferred materials are selected from 10mil thick MELINEX® 329 or KAPTON®, which are coated with 50±4 nm goldwithin-lot C.V. of <5% by: Techni-Met Advanced Depositions, Inc.,Windsor, Conn., USA. It is appreciated that the base 212 may be eitherpurchased pre-coated with conductive material 216 or may be coated bysputtering or vapor deposition, in accordance with this disclosure. Itis further appreciated that the thickness of the conductive material canvary in accordance with this disclosure.

Spacer 214 is illustratively positioned on the top surface 232 of thebase 212 adjacent to end 224. Spacer 214 has an upper surface 236 and alower surface 238 (FIG. 9) facing the base 212. Referring now to FIG. 2,the spacer 214 has edges 240, 242, 244, 246. Illustratively, spacer 214has a length of about 6 mm, a width of about 10 mm and a height of about4 mil. It is appreciated, however that these values are merelyillustrative and that the biosensor may be formed without a spacer andthat the dimensions of the spacer 214 may vary in accordance with thepresent disclosure.

Spacer 214 is formed from an insulating material, so that it will notprovide an electrical connection between electrodes formed from theconductive material 216. Non-limiting examples of suitable insulatingmaterials include glass, ceramics, polymers, photoimageable coverlaymaterials, and photoresists—non-limiting examples of which are disclosedin U.S. patent application Ser. No. 10/264,891, filed Oct. 4, 2002, thedisclosure of which is incorporated herein by reference. Illustratively,spacer 214 is formed of 4 mil MELINEX® polyester film, which ispreferred for use with whole blood samples. It is appreciated, however,that when the sample is plasma or serum, 1-2 mil film may be preferredfor use in accordance with this disclosure. It is appreciated, howeverthat these values are merely illustrative and that the composition anddimension of the spacer 214 may vary in accordance with the desiredheight of the sample-receiving chamber.

A slit or void 248 is formed in the spacer 214 and extends from the edge240 toward the edge 242. The slit 248 defines at least the length andwidth of the sample-receiving chamber 220 and is defined by edges 249.Illustratively, the slit 248 has a length of 5 mm, a width of 1 mm, anda height of 0.1 mm, but may have a variety of lengths and widths inaccordance with the present disclosure. It is further appreciated thatthe edges 249 of the slit may also be curved or angular in accordancewith this disclosure.

As shown in FIG. 1, the cover 218 is positioned on the upper surface 236of spacer 214. Cover 218 has a first surface 250 and a second surface252 (FIG. 9) facing the base 212. Further, the cover 218 has edges 254,256, 258, 260. As shown in FIG. 1, the cover 218 has a length that isless than the length of the slit 248. Illustratively, cover 218 has alength of about 4 mm, a width of about 10 mm and a height of about 0.1mm. It is appreciated, however that these values are merely illustrativeand that the biosensor may be formed without a cover and that thedimensions of the cover 218 may vary in accordance with the presentdisclosure.

The cover 218 is illustratively formed of a clear material having ahydrophilic adhesive layer in proximity to the spacer. Non-limitingexamples of materials suitable for cover 218 include polyethylene,polypropylene, polyvinylchloride, polyimide, glass, or polyester. Apreferred material for cover 218 is 100 μm polyester. A preferredadhesive is ARCare 8586 having a MA-55 hydrophilic coating, commerciallyavailable from Adhesives Research Inc., Glen Rock, Pa. Further, it isappreciated that the cover may have markings in accordance with thisdisclosure.

The slit 248 in the spacer 214, together with the cover 218, and thebase 212, form the sample-receiving chamber 220 (FIG. 9), which acts toexpose reagent 264 to a fluid to be tested from a user of biosensor 210.This sample-receiving chamber 220 can act as a capillary channel,drawing the fluid to be tested from the opening 221 onto a sensingregion of the conductive material 216 and toward a vent 262. It isappreciated that the biosensor may be formed without a spacer inaccordance with this disclosure and that in addition to or instead ofthe spacer and the cover, a variety of dielectric materials may coverthe base 212 exposing only selected portions of the conductive materialin accordance with this disclosure. Moreover, it is appreciated thatwhen present, the dimensions of the channel 220 may vary in accordancewith this disclosure.

FIG. 2 illustrates the conductive material 216 defining electrodesystems comprising a first electrode set 266 and a second electrode set268, and corresponding traces 279, 277 and contact pads 278, 282,respectively. The conductive material 216 may contain pure metals oralloys, or other materials, which are metallic conductors. Preferably,the conductive material is transparent at the wavelength of the laserused to form the electrodes and of a thickness amenable to rapid andprecise processing. Non-limiting examples include aluminum, carbon,copper, chromium, gold, indium tin oxide (ITO), palladium, platinum,silver, tin oxide/gold, titanium, mixtures thereof, and alloys ormetallic compounds of these elements. Preferably, the conductivematerial includes noble metals or alloys or their oxides. Mostpreferably, the conductive material includes gold, palladium, aluminum,titanium, platinum, ITO and chromium. The conductive material ranges inthickness from about 10 nm to 80 nm, more preferably, 30 nm to 70 nm.FIGS. 1-3, 6, and 8-9 illustrate the biosensor 210 with a 50 nm goldfilm. It is appreciated that the thickness of the conductive materialdepends upon the transmissive property of the material and other factorsrelating to use of the biosensor.

Illustratively, the conductive material 216 is ablated into twoelectrode systems that comprise sets 266, 268. In forming these systems,the conductive material 216 is removed from at least about 5% of thesurface area of the base 212, more preferably at least about 50% of thesurface area of the base 212, and most preferably at least about 90% ofthe surface area of the base 212. As shown in FIG. 2, the onlyconductive material 216 remaining on the base 212 forms at least aportion of an electrode system.

While not illustrated, it is appreciated that the resulting patternedconductive material can be coated or plated with additional metallayers. For example, the conductive material may be copper, which isthen ablated with a laser, into an electrode pattern; subsequently, thecopper may be plated with a titanium/tungsten layer, and then a goldlayer, to form the desired electrodes. Preferably, a single layer ofconductive material is used, which lies on the base 212. Although notgenerally necessary, it is possible to enhance adhesion of theconductive material to the base, as is well known in the art, by usingseed or ancillary layers such as chromium nickel or titanium. Inpreferred embodiments, biosensor 210 has a single layer of gold,palladium, platinum or ITO.

As shown in FIGS. 2 and 9, the biosensor 210 includes an electrodesystem comprising at least a working electrode and a counter electrodewithin the sample-receiving chamber 220. The sample-receiving chamber220 is configured such that sample fluid entering the chamber is placedin electrolytic contact with both the working electrode and the counterelectrode. This allows electrical current to flow between the electrodesto effect the electrooxidation or electroreduction of the analyte or itsproducts.

Referring now to FIG. 3, the first electrode set 266 of the electrodesystem includes two electrodes 270, 272. Illustratively, electrode 270is a working electrode and electrode 272 is a counter electrode. Theelectrodes 270, 272 each have a single element or finger 280 that is incommunication with a contact pad 278 via a connecting trace 279 (shownin FIG. 2). The electrode fingers 280 of the electrodes 270, 272cooperate to define an electrode pattern formed as a macroelectrodearray. It is appreciated, as will be discussed hereafter, that theelectrodes 270, 272 can include more than one finger each in accordancewith this disclosure. It is further appreciated that the shape, size andrelative configuration of the electrodes or electrode fingers may varyin accordance with the present disclosure.

As shown in FIG. 2, the second electrode set 268 includes two electrodes274, 276. Illustratively, electrode 274 is a working electrode andelectrode 276 is a counter electrode. Further, the electrodes 274, 276each have five electrode elements or fingers 284 that are incommunication with a contact pad 282 via a connecting trace 277.Referring now to FIG. 3, the electrode fingers 284 cooperate to definean electrode pattern formed as an interlaced microelectrode array. Whilefive electrode fingers 284 are illustrated, it is appreciated that theelements of electrodes 274, 276 can each be formed with greater or fewerthan five electrode fingers in accordance with this disclosure. It isfurther appreciated that the shape, size and relative configuration ofthe electrodes may vary in accordance with the present disclosure.

It is appreciated that the values for the dimensions of the electrodesets 266, 268 as illustrated in FIG. 2 are for a single specificembodiment, and these values may be selected as needed for the specificuse. For example, the length of the electrode sets may be any length upto the length of the base, depending upon the orientation of theelectrode sets on the base. Further, it is appreciated that the width ofthe conducting traces in communication with the electrode sets may vary,a non-limiting example of which is from about 0.4 mm to about 5 mm. Itis further appreciated that the width of each contact pad may vary, anon-limiting example of which is from about 1 mm to about 5 mm. Theelectrode patterns shown in FIG. 2 are symmetric, however this is notrequired, and irregular or asymmetric patterns (or electrode shapes) arepossible in accordance with this disclosure. Further, the number ofelectrode sets on the base 212 may vary, and therefore each base 212 cancontain, for example 1 to 1000 electrode sets, preferably 2 to 20electrode sets, more preferably 2 to 3 electrode sets.

Referring again to the first electrode set 266 of FIG. 3, each electrodefinger 280 is defined by an inner edge 281, an outer edge 283, andopposite third and fourth edges 285, 287. Each edge 218, 283, 285, 287has a smooth edge quality. As discussed earlier, the edge quality of theelectrodes 270, 272 is defined by the edge's deviation from atheoretical line extending between first and second points. Thefollowing description of deviations can apply to each edge of electrodes270, 272 of biosensor 210. For clarity purposes, however, only the edge281 of electrode 270 will be discussed hereafter.

As shown in FIG. 3, the edge 281 of electrode 270 extends between points289, 291 located on the base 212. Points 289, 291 are located atopposite ends of the inner edge 281, which represents the entire lengthof the gap 286 between electrodes 280. It is appreciated that the points289, 291 may be positioned at a variety of locations and at a variety ofdistances relative to one another depending upon the length of thedesired edge in accordance with this disclosure. However, the length ofinterest will typically be the entire length over which a gap extends,since the smoothness of the adjacent edges is normally most importantover this entire length.

FIG. 4 illustrates the theoretical line 293 that extends exactly betweenpoints 289, 291. That is, line 293 represents the ideal or desired edgethat would be obtained if the process of forming the electrodes wereperfect. However, at any given point along the length of line 293, theedge 281 will be spaced in either direction from theoretical line 293 bya distance “d_(i).” The distance d_(i) varies from zero to a maximumvalue depending upon where it happens to be measured, as shown, e.g.,with reference to distances d₁, d₂, d₃ and d₄ in FIG. 4. A standarddeviation of this distance over the length of line 293 is less thanabout 6 μm in accordance with this disclosure, creating an edge with asmooth edge quality. In preferred embodiments, the standard deviation ofthe edge 281 from theoretical line 293 is less than 2 μm, and mostpreferably less than 1.0 μm. An example of this deviation from mean ortheoretical is illustrated in FIG. 10.

The edge quality illustrated in FIG. 10 was measured using Micro-Measuresystem commercially available from LPKF Laser Electronic GmbH, ofGarbsen, Germany with Metric 6.21 software. The Metric software allowsthe display and measuring of video images on a PC. Measurements weremade by capturing the image and then allowing the software to place a 10μm grid over the image. The grid was aligned with the edge by moving theelectrode structure under the measurement objective. (By physicallymanipulating the image, the edge can be vertically aligned to beparallel with the grid.) Using the software, measurements from the gridline to the electrode edge were then made at 10 μm intervals along thelength of a line 250 μm long using a point-to-point process. Theeffective video magnification to video screen was 575×. (Using objectiveQ750). Video magnification=Actual measured “Scale length” on the videoscreen (μm)/Scale value (μm). For example, 115000 μcm/200 μm=575×.

In one analysis of an electrical pattern formed using the principles ofthe present invention, the deviation from mean of the edges was measuredusing a QVH-606 PRO Vision Measuring System (computer-controllednon-contact measurement system), commercially available from MitutoyoAmerica Corporation, Aurora, Ill. with an effective magnification tovideo screen=470×. Standard deviations were calculated from measurementsmade at an average interval of 0.69 μm for a length of at least 250 μm.Other settings: Ring lighting (Intensity 89, Position 60), EdgeDetection (Edge Slope=Falling, Edge Detection TH=169, THS=18.5, THR=0.5Scan Interval=1). The standard deviation from the mean value was lessthan about 2 μm.

Referring again to FIG. 4, the line 293 is illustratively a straightline. It is appreciated, however, that the shape of the line 293 may becurved or angular, so long as the standard deviation of the distance ofedge 281 from that line 293 over the length of the edge is less thanabout 6 μm.

The electrode fingers 280, as shown in FIG. 3, are separated from oneanother by an electrode gap 286, which corresponds to the feature sizeof the electrode pattern of the electrode set 266. The electrode gap 286shown in FIG. 3 is shown as formed by two straight edges 281. However,as just noted, the placement of edges 281 varies from theoretical value293 (FIG. 4) by a distance that varies along the length of the edge.Illustratively, in biosensor 210, the electrically insulative materialof the top surface 232 is exposed between the electrode fingers 280along a length 290. It is appreciated, however, that rather than topsurface 232 being exposed, the base can be coated with materials, orrecesses can be formed between the electrodes as disclosed in U.S.patent application Ser. No. 09/704,145, filed on Nov. 1, 2000, now U.S.Pat. No. 6,540,890, the disclosure of which is incorporated herein byreference.

As shown in FIGS. 3 and 5, the inner edges 281 of electrode fingers 280have an equal length, illustrated by the numeral 290 and are separatedfrom one another by the electrode gap 286, whose length is alsorepresented by length 290. Because the two edges 281 defining gap 286are not perfect, gap 286 will in fact vary in width and placement overits length, as shown with reference to gaps 292 a-292 d in FIG. 5. Whenthe deviations of the two edges defining gap 286 are in the samedirection, they tend to cancel each other as to width deviation, atleast in part, and cause a net shift in placement of the gap, asillustrated with respect to reference numerals 292 c and 292 d of FIG.5. A theoretical gap can be defined by two theoretical lines 293associated with edges 281. The quality of the gap or its deviation fromthe theoretical gap can be specified in terms of the quality of the twoindividual edges defining it. Preferably, the smoothness standarddeviation of both edges defining gap 286 is less 6 μm, preferably lessthan 2.0 μm, and most preferably less than 1 μm.

The electrode fingers 284, which define the elements of electrodes 274,276 are illustrated in FIGS. 3 and 6. For clarity purposes, however,only three of these electrode fingers 284 will be discussed hereafter asthey are illustrated in FIG. 6. Each electrode finger 284 is defined bya first edge 296 and a second edge 297. Further, adjacent fingers 284have spaced-apart third and fourth edges 298, 299 respectively. Theseedges 296, 297, 298, 299 of fingers 284 can also have a smooth edgequality. As previously described with reference to electrodes 270, 272,the edge quality of the electrodes 274, 276 is defined by the respectiveedge's deviation from a line extending between first and second points.The following description of deviations will apply to each edge ofelectrode fingers 284 of biosensor 210. For clarity purposes, however,only one edge 296 of electrode finger 284 will be discussed hereafter.

The edge 296 of electrode finger 284 extends between first and secondpoints 301, 302 located on the base 212. As shown in FIG. 7, atheoretical line 300 extends exactly between points 301, 302, which istypically the length of the gap formed by edge 296 and 297. A standarddeviation of the varying distance of edge 296 from line 300 is less thanabout 6 μm, in accordance with this disclosure, creating an edge with asmooth edge quality. In preferred embodiments, the standard deviation ofthe edge 296 from theoretical line 300 is less than 2 μm, and mostpreferably less than 1.0 μm. Illustratively, the line 300 is a straightline. It is appreciated, however, that the shape of the line 300 may becurved or angular. It is also appreciated that the specific positions offirst and second locations 300, 301 on the surface 232 may vary inaccordance with the disclosure, although the lengths of most importanceare typically the entire length of the gaps between these closely spacedelectrode fingers.

Referring again to FIG. 3, the electrode fingers 284 are separated fromone another by an electrode gap 288, which corresponds to the featuresize of the electrode pattern of the electrode set 268. The electrodegap 288 relates to the width between adjacent edges 296, 297 of fingers284. Because the two edges defining gap 288 are not perfect, gap 288will in fact vary in position and placement over its length.Illustratively, in biosensor 210, the electrically insulative materialof the base 212 is exposed between the electrode fingers 284 along alength 303. It is appreciated, however, that rather than top surface 232being exposed, the base can be coated with materials, or recesses can beformed between the electrodes as disclosed in U.S. patent applicationSer. No. 09/704,145, filed on Nov. 1, 2000, now U.S. Pat. No. 6,540,890,entitled “Biosensor”, the disclosure of which is incorporated herein byreference.

The electrode gap 288, which corresponds to the feature size of theelectrode pattern of the electrode set 268 is different than the featuresize of the electrode pattern of the electrode set 266. Illustratively,the feature size, or gap 288 between the electrode fingers 284 has awidth of about 100 μm or less, including about 1 μm to about 100 μm,even more preferably 75 μm or less, including about 17 μm to about 50μm.

It is appreciated that the electrode gap for a microelectrode array canvary. For example, it is understood that the electrode gap can be lessthan 1 μm in accordance with the present disclosure. The size of theachievable gap is dependent upon the quality of the optics, thewavelength of the laser, and the window size of a mask field.

As illustrated in FIG. 3, the gap 288 has a width along a length 303 ofthe opposing edges 296, 297 of the electrode fingers 284. Like gap 286,the quality of gap 286 or its deviation from a theoretical gap can bespecified in terms of the quality of the two individual edges definingit. Preferably, the smoothness standard deviation of both edges defininggap 286 is less 6 μm, preferably less than 2.0 μm, and most preferablyless than 1 μm.

Referring now to FIG. 9, the electrode fingers 284 are covered with thereagent 264 and may be used to provide electrochemical probes forspecific analytes. The starting reagents are the reactants or componentsof the reagent, and are often compounded together in liquid form beforeapplication to the ribbons or reels, or in capillary channels on sheetsof electrodes. The liquid may then evaporate, leaving the reagent insolid form. The choice of a specific reagent depends on the specificanalyte or analytes to be measured, and is not critical to the presentinvention. Various reagent compositions are well known to those ofordinary skill in the art. It is also appreciated that the placementchoice for the reagent on the base may vary and depends on the intendeduse of the biosensor. Further, it is appreciated that the techniques forapplying the reagent onto the base may vary. For example, it is withinthe scope of the present disclosure to have the reagent screen-printedonto the fingers.

A non-limiting example of a dispensable reagent for measurement ofglucose in a human blood sample contains 62.2 mg polyethylene oxide(mean molecular weight of 100-900 kilodaltons), 3.3 mg NATROSOL 250 M,41.5 mg AVICEL RC-591 F, 89.4 mg monobasic potassium phosphate, 157.9 mgdibasic potassium phosphate, 437.3 mg potassium ferricyanide, 46.0 mgsodium succinate, 148.0 mg trehalose, 2.6 mg TRITON X-100 surfactant,and 2,000 to 9,000 units of enzyme activity per gram of reagent. Theenzyme is prepared as an enzyme solution from 12.5 mg coenzyme PQQ and1.21 million units of the apoenzyme of quinoprotein glucosedehydrogenase, forming a solution of quinoprotein glucose dehydrogenase.This reagent is further described in U.S. Pat. No. 5,997,817, thedisclosure of which is expressly incorporated herein by reference.

A non-limiting example of a dispensable reagent for measurement ofhematocrit in a sample contains oxidized and reduced forms of areversible electroactive compound (potassium hexacyanoferrate (III)(“ferricyanide”) and potassium hexacyanoferrate (II) (“ferrocyanide”),respectively), an electrolyte (potassium phosphate buffer), and amicrocrystalline material (Avicel RC-591F—a blend of 88%microcrystalline cellulose and 12% sodium carboxymethyl-cellulose,available from FMC Corp.). Concentrations of the components within thereagent before drying are as follows: 400 millimolar (mM) ferricyanide,55 mM ferrocyanide, 400 mM potassium phosphate, and 2.0% (weight:volume) Avicel. A further description of the reagent for a hematocritassay is found in U.S. Pat. No. 5,385,846, the disclosure of which isexpressly incorporated herein by reference.

Non-limiting examples of enzymes and mediators that may be used inmeasuring particular analytes in biosensors of the present invention arelisted below in Table 1. TABLE 1 Mediator Analyte Enzymes (OxidizedForm) Additional Mediator Glucose Glucose Dehydrogenase Ferricyanide andDiaphorase Osmium complexes, nitrosoanaline complexes GlucoseGlucose-Dehydrogenase Ferricyanide (Quinoprotein) CholesterolCholesterol Esterase and Ferricyanide 2,6-Dimethyl-1,4- CholesterolOxidase Benzoquinone 2,5-Dichloro-1,4- Benzoquinone or PhenazineEthosulfate HDL Cholesterol Esterase Ferricyanide 2,6-Dimethyl-1,4-Cholesterol and Cholesterol Oxidase Benzoquinone 2,5-Dichloro-1,4-Benzoquinone or Phenazine Ethosulfate Triglycerides Lipoprotein Lipase,Ferricyanide or Phenazine Methosulfate Glycerol Kinase, and PhenazineGlycerol-3-Phosphate Ethosulfate Oxidase Lactate Lactate OxidaseFerricyanide 2,6-Dichloro-1,4- Benzoquinone Lactate LactateDehydrogenase Ferricyanide and Diaphorase Phenazine Ethosulfate, orPhenazine Methosulfate Lactate Diaphorase Ferricyanide PhenazineEthosulfate, or Dehydrogenase Phenazine Methosulfate Pyruvate PyruvateOxidase Ferricyanide Alcohol Alcohol Oxidase Phenylenediamine BilirubinBilirubin Oxidase 1-Methoxy- Phenazine Methosulfate Uric Acid UricaseFerricyanide

In some of the examples shown in Table 1, at least one additional enzymeis used as a reaction catalyst. Also, some of the examples shown inTable 1 may utilize an additional mediator, which facilitates electrontransfer to the oxidized form of the mediator. The additional mediatormay be provided to the reagent in lesser amount than the oxidized formof the mediator. While the above assays are described, it iscontemplated that current, charge, impedance, conductance, potential, orother electrochemically indicated property of the sample might beaccurately correlated to the concentration of the analyte in the samplewith biosensors in accordance with this disclosure.

Another non-limiting example of a suitable dispensable reagent for usewith biosensors of the present invention is nitrosoanaline reagent,which includes a PQQ-GDH and para-Nitroso-Aniline mediator. A protocolfor the preparation of the nitrosoanaline reagent is the same in allrespects as disclosed in U.S. patent application Ser. No. 10/688,312,entitled “System And Method For Analyte Measurement Using AC Phase AngleMeasurement”, filed Oct. 17, 2003, the disclosure of which isincorporated herein by reference. The reagent mass composition—prior todispensing and drying is as set forth in Table 2. TABLE 2 Mass forComponent % w/w 1 kg solid Polyethylene oxide (300 KDa) 0.8054%  8.0539g solid NATROSOL ® 250 M 0.0470%  0.4698 g solid AVICEL ® RC-591F0.5410%  5.4104 g solid Monobasic potassium phosphate 1.1437%  11.4371 g(anhydrous) solid Dibasic potassium phosphate 1.5437%  15.4367 g(anhydrous) solid Sodium Succinate hexahydrate 0.5876%  5.8761 g solidPotassium Hydroxide 0.3358%  3.3579 g solid Quinoprotein glucosedehydrogenase 0.1646%  1.6464 g (EncC#: 1.1.99.17) solid PQQ 0.0042% 0.0423 g solid Trehalose 1.8875%  18.8746 g solid Mediator BM 31.11440.6636%  6.6363 g solid TRITON ® X-100 0.0327%  0.3274 g solvent Water92.2389% 922.3888 g % Solids 0.1352687 Target pH 6.8 Specific EnzymeActivity Used (U/mg 689 DCIP Dispense Volume per Biosensor 4.6 mg

A coatable reagent suitable for use with the present disclosure is asfollows in Table 3. TABLE 3 Component % w/w Mass for 1 kg Keltrol F,xanthan gum 0.2136%  2.1358 g Sodium Carboxymethylcellulose (CMC)0.5613%  5.6129 g Polyvinylpyrrolidone, (PVP K25) 1.8952%  18.9524 gPROPIOFAN ®, 2.8566%  28.5657 g GlucDOR 0.3310%  3.3098 g PQQ 0.0092% 0.0922 g Sipernat 320 DS 2.0039%  20.0394 g Na-Succinat × 6H2O 0.4803% 4.8027 g Trehalose 0.4808%  4.8081 g KH₂PO₄ 0.4814%  4.8136 g K₂HPO₄1.1166%  11.1658 g Mediator 31.1144 0.6924%  6.9242 g Mega 8 0.2806% 2.8065 g Geropon T 77 0.0298%  0.2980 g KOH 0.1428%  1.4276 g Water88.4245% 884.2453 g % Solids 11.5755 Target pH  7.0 Specific EnzymeActivity Used (U/mg  2.23 DCIP Coat Weight 55 g/m²

Biosensor 210 is illustratively manufactured using two apparatuses 10,10′, shown in FIGS. 17-18 and 19, respectively. It is appreciated thatunless otherwise described, the apparatuses 10, 10′ operate in a similarmanner. Referring first to FIG. 17, biosensor 210 is manufactured byfeeding a roll of ribbon or web 20 having an 80 nm gold laminate, whichis about 40 mm in width, into a custom fit broad field laser ablationapparatus 10. The apparatus 10 comprises a laser source 11 producing abeam of laser light 12, a chromium-plated quartz mask 14, and optics 16.It is appreciated that while the illustrated optics 16 is a single lens,optics 16 is preferably a variety of lenses that cooperate to make thelight 12 in a pre-determined shape or image that is then projected ontothe web of base substrate 20.

A non-limiting example of a suitable ablation apparatus 10 (FIGS. 17-18)is a customized MicrolineLaser 200-4 laser system commercially availablefrom LPKF Laser Electronic GmbH, of Garbsen, Germany, which incorporatesan LPX-400, LPX-300 or LPX-200 laser system commercially available fromLambda Physik AG, Gottingen, Germany and a chromium-plated quartz maskcommercially available from International Phototool Company, ColoradoSprings, Co.

For the MicrolineLaser 200-4 laser system (FIGS. 17-18), the lasersource 11 is a LPX-200 KrF-UV-laser. It is appreciated, however, thathigher wavelength UV lasers can be used in accordance with thisdisclosure. The laser source 11 works at 248 nm, with a pulse energy of600 mJ, and a pulse repeat frequency of 50 Hz. The intensity of thelaser beam 12 can be infinitely adjusted between 3% and 92% by adielectric beam attenuator (not shown). The beam profile is 27×15 mm²(0.62 sq. inch) and the pulse duration 25 ns. The layout on the mask 14is homogeneously projected by an optical elements beam expander,homogenizer, and field lens (not shown). The performance of thehomogenizer has been determined by measuring the energy profile. Theimaging optics 16 transfer the structures of the mask 14 onto the ribbon20. The imaging ratio is 2:1 to allow a large area to be removed on theone hand, but to keep the energy density below the ablation point of theapplied chromium mask on the other hand. While an imaging of 2:1 isillustrated, it is appreciated that the any number of alternative ratiosare possible in accordance with this disclosure depending upon thedesired design requirements. The ribbon 20 moves as shown by arrow 25 toallow a number of layout segments to be ablated in succession.

The positioning of the mask 14, movement of the ribbon 20, and laserenergy are computer controlled. As shown in FIG. 17, the laser beam 12is projected onto the ribbon 20 to be ablated. Light 12 passing throughthe clear areas or windows 18 of the mask 14 ablates the metal from theribbon 20. Chromium coated areas 24 of the mask 14 blocks the laserlight 12 and prevent ablation in those areas, resulting in a metallizedstructure on the ribbon 20 surface. Referring now to FIG. 18, a completestructure of electrical components may require additional ablation stepsthrough a second mask 14′. It is appreciated that depending upon theoptics and the size of the electrical component to be ablated, that onlya single ablation step or greater than two ablation steps may benecessary in accordance with this disclosure. Further, it is appreciatedthat instead of multiple masks, that multiple fields may be formed onthe same mask in accordance with this disclosure.

Specifically, a second non-limiting example of a suitable ablationapparatus 10′ (FIG. 19) is a customized laser system commerciallyavailable from LPKF Laser Electronic GmbH, of Garbsen, Germany, whichincorporates a Lambda STEEL (Stable energy eximer laser) laser systemcommercially available from Lambda Physik AG, Göttingen, Germany and achromium-plated quartz mask commercially available from InternationalPhototool Company, Colorado Springs, Co. The laser system features up to1000 mJ pulse energy at a wavelength of 308 nm. Further, the lasersystem has a frequency of 100 Hz. The apparatus 10′ may be formed toproduce biosensors with two passes as shown in FIGS. 17 and 18, butpreferably its optics permit the formation of a 10×40 mm pattern in a 25ns single pass.

While not wishing to be bound to a specific theory, it is believed thatthe laser pulse or beam 12 that passes through the mask 14, 14′, 14″ isabsorbed within less than 1 μm of the surface 232 on the ribbon 20. Thephotons of the beam 12 have an energy sufficient to causephoto-dissociation and the rapid breaking of chemical bonds at themetal/polymer interface. It is believed that this rapid chemical bondbreaking causes a sudden pressure increase within the absorption regionand forces material (metal film 216) to be ejected from the polymer basesurface. Since typical pulse durations are around 20-25 nanoseconds, theinteraction with the material occurs very rapidly and thermal damage toedges of the conductive material 216 and surrounding structures isminimized. The resulting edges of the electrical components have highedge quality and accurate placement as contemplated by the presentinvention.

Fluence energies used to remove or ablate metals from the ribbon 20 aredependent upon the material from which the ribbon 20 is formed, adhesionof the metal film to the base material, the thickness of the metal film,and possibly the process used to place the film on the base material,i.e. supporting and vapor deposition. Fluence levels for gold onKALADEX® range from about 50 to about 90 mJ/cm², on polyimide about 100to about 120 mJ/cm², and on MELINEX® about 60 to about 120 mJ/cm². It isunderstood that fluence levels less than or greater than the abovementioned can be appropriate for other base materials in accordance withthe disclosure.

Patterning of areas of the ribbon 20 is achieved by using the masks 14,14′. Each mask 14, 14′ illustratively includes a mask field 22containing a precise two-dimensional illustration of a pre-determinedportion of the electrode component patterns to be formed. FIG. 17illustrates the mask field 22 including contact pads and a portion oftraces. As shown in FIG. 18, the second mask 14′ contains a secondcorresponding portion of the traces and the electrode patternscontaining fingers. As previously described, it is appreciated thatdepending upon the size of the area to be ablated, the mask 14 cancontain a complete illustration of the entire electrode pattern for eachbiosensor (FIG. 19), or partial patterns different from thoseillustrated in FIGS. 17 and 18 in accordance with this disclosure.Preferably, it is contemplated that in one aspect of the presentinvention, the entire pattern of the electrical components on the teststrip are laser ablated at one time, i.e., the broad field encompassesthe entire size of the test strip (FIG. 19), or even encompasses theentire size of two or more test strips (not shown). In the alternative,and as illustrated in FIGS. 17 and 18, portions of the entire biosensorare done successively.

While mask 14 will be discussed hereafter, it is appreciated that unlessindicated otherwise, the discussion will apply to masks 14′, 14″ aswell. Referring to FIG. 17, areas 24 of the mask field 22 protected bythe chrome will block the projection of the laser beam 12 to the ribbon20. Clear areas or windows 18 in the mask field 22 allow the laser beam12 to pass through the mask 14 and to impact predetermined areas of theribbon 20. As shown in FIG. 17, the clear area 18 of the mask field 22corresponds to the areas of the ribbon 20 from which the conductivematerial 216 is to be removed.

Further, the mask field 22 has a length shown by line 30 and a width asshown by line 32. Given the imaging ratio of 2:1 of the LPX-200, it isappreciated that the length 30 of the mask is two times the length of alength 34 of the resulting pattern and the width 32 of the mask is twotimes the width of a width 36 of the resulting pattern on ribbon 20. Theoptics 16 reduces the size of laser beam 12 that strikes the ribbon 20.It is appreciated that the relative dimensions of the mask field 22 andthe resulting pattern can vary in accordance with this disclosure. Mask14′ (FIG. 18) is used to complete the two-dimensional illustration ofthe electrical components.

Continuing to refer to FIG. 17, in the laser ablation apparatus 10 theexcimer laser source 11 emits beam 12, which passes through thechrome-on-quartz mask 14. The mask field 22 causes parts of the laserbeam 12 to be reflected while allowing other parts of the beam to passthrough in the form of an image of part or all of an electrode pattern.The image or part of laser beam 12 that passes through mask 14 in turncreates a pattern on the gold film where impacted by the laser beam 12.It is appreciated that ribbon or web 20 can be stationary relative toapparatus 10 or move continuously on a roll through apparatus 10.Accordingly, non-limiting rates of movement of the ribbon 20 can be fromabout 0 m/min to about 100 m/min, more preferably about 30 m/min toabout 60 m/min. It is appreciated that the rate of movement of theribbon 20 is limited only by the apparatus 10 selected and may wellexceed 100 m/min depending upon the pulse duration of the laser source11 in accordance with the present disclosure.

Once the pattern of the mask 14 is created on the ribbon 20, the ribbonis rewound and fed through the apparatus 10 again, with mask 14′ (FIG.18). It is appreciated that laser apparatus 10 could, alternatively, bepositioned in series in accordance with this disclosure. A detaileddescription of the step and repeat process is found in U.S. ApplicationSer. No. 60/480,397, filed Jun. 20, 2003, entitled “Devices And MethodsRelating To Analyte Sensors”, the disclosure of which is incorporatedherein by reference. Thus, by using masks 14, 14′, large areas of theweb or ribbon 20 can be patterned using step-and-repeat processesinvolving multiple mask fields 22 in the same mask area to enable theeconomical creation of intricate electrode patterns and other electricalcomponents on a substrate of the base, the precise edges of theelectrode components, and the removal of greater amounts of the metallicfilm from the base material.

FIG. 20 is a non-limiting schematic of an electrode set ribbon 124formed in accordance with the present disclosure, although having anelectrode pattern different from that illustrated in FIGS. 17 and 18.The ribbon 124 includes a plurality of panels 120, each of whichincludes a plurality of electrode systems 116. Each system includes twoelectrodes, both labeled 104 and having a sensing region 110. Also shownis the original metallic laminate ribbon 122 that is subject to laserablation to form the electrode set ribbon 124. The width of the ribbon122 is selected to accommodate the laser ablation system 10, 10′, andmay be, for example, 40 to 0.4 inches (1.2 m to 10.25 mm). The ribbonmay be any length, and is selected based on the desired number ofelectrode sets, and/or the ease of handling and transport of theribbons. The size of each individual panel is selected to fitconveniently on the ribbon, and therefore each panel may contain 1 to1000 electrode sets, preferably 2 to 20 electrode sets.

Once the complete electrode patterns are created, it is appreciated thatthe ribbon 20 may be coupled to a spacer and a cover using any number ofwell-known commercially available methods. A non-limiting example of asuitable method of manufacture, is described in detail in U.S.Application Ser. No. 60/480,397, filed Jun. 20, 2003, entitled “DevicesAnd Methods Relating To Analyte Sensors”, the disclosure of which isincorporated herein by reference. In summary, however, it is appreciatedthat a reagent film is placed upon the ribbon and dried conventionallywith an in-line drying system. The rate of processing is nominally 30-38meters per minute and depends upon the rheology of the reagent. Reagentssuitable for the biosensor 210 are given above, but a preferable reagentis set out in Table 2.

The materials are processed in continuous reels such that the electrodepattern is orthogonal to the length of the reel, in the case of thebase. Once the base has been coated, the spacer material is laminatedonto the coated ribbon 20. Prior to laminating the spacer material,however, a portion of the spacer material is removed, thereby forming aslit. A punching process is used to remove the unneeded portion of thespacer. The die set governs the shape of the slit. The resultingslit-spacer is placed in a reel-to-reel process onto the base. A coveris then laminated onto the spacer using a reel-to reel process. Thebiosensors can then be produced from the resulting reels of material bymeans of slitting and cutting.

The slit in the spacer preferably forms a capillary fill space betweenthe base and the cover. A hydrophobic adhesive on the spacer preventsthe test sample from flowing into the reagent under the spacer andtherefore the fill space defines the test chamber volume. It isappreciated that the chamber volume can vary in accordance with thisdisclosure depending upon the application of the biosensor. Anon-limiting detailed description of suitable fill volumes is found inU.S. Application Ser. No. 60/480,397, noted above.

As discussed above, biosensor 210 has two electrode patterns havingdifferent feature sizes on a common planar surface and thus achievesmultiple functionalities on that surface. Preferably, electrode set 266has an electrode pattern formed as a macro electrode array with a firstpre-defined feature size. A non-limiting example of a suitablefunctionality of the macroelectrode array is hematocrit levelcorrection, which is described in U.S. patent application Ser. No.10/688,312, entitled “System And Method For Analyte Measurement Using ACPhase Angle Measurement”, filed Oct. 17, 2003, the disclosure of whichis incorporated herein by reference. Further, it is appreciated thatduring use, a test meter (not shown) applies a voltage to one electrodeand measures the current response at the other electrode to obtain asignal as described in U.S. patent application Ser. No. 10/688,312 justnoted.

Electrode set 268 has an electrode pattern formed as an interlacedmicroelectrode array with a second pre-defined feature size. Anon-limiting example of a suitable functionality of the microelectrodearray is glucose estimation, which is also described in U.S. patentapplication Ser. No. 10/688,312. Further, it is appreciated that duringuse, a test meter (not shown) applies a voltage to one electrode andmeasures the current response at the other electrode to obtain a signalas described in U.S. patent application Ser. No. 10/688,312.

In operation, a user places his or her lanced finger at opening 221 ofbiosensor 210. A liquid sample (whole blood) flows from the finger intothe opening 221. The liquid sample is transported via capillary actionthrough the sample-receiving chamber 220 and across the fingers 280 ofthe element of the electrode set 266. Subsequently, the liquid sampleflows through the sample-receiving chamber 220 toward vent 262 and intoengagement with the reagent 264 situated upon the fingers 284 of theelement of the electrode set 268. As discussed above, hematocritcorrection values are determined from the interaction of the liquidsample with the fingers 280 and a glucose determination from theinteraction of the liquid sample/reagent mixture with the fingers 284.While hematocrit and glucose determination functionalities are describedwith reference to biosensor 210, it is appreciated that the electrodepatterns, may be used for a variety of functionalities in accordancewith the present disclosure.

The processes and products described include disposable biosensors,especially for use in diagnostic devices. However, also included areelectrochemical biosensors for non-diagnostic uses, such as measuring ananalyte in any biological, environmental, or other, sample. In addition,it is appreciated that various uses and available functions of thebiosensor may stand alone or be combined with one another in accordancewith this disclosure.

As discussed below with reference to FIGS. 11-16, each of the disclosedbiosensors operates from the standpoint of a user in a manner similar tothat described above with reference from 210. In addition, likecomponents of the biosensors are numbered alike.

Referring now to FIG. 11, a biosensor 310 is formed and manufactured ina manner similar to biosensor 210 except for the pattern of theconductive material 216 positioned on the base 212. The conductivematerial 216 of biosensor 310 defines a first electrode system 366 and asecond electrode system 368. The electrode systems 366, 368 are similarto the systems of biosensor 210 except for the resulting pattern of theconnecting traces 377, 379 and contact pads 378, 383 on the base 212. Itis submitted that the traces 377, 379 and pads 378, 383 may take on avariety of shapes and sizes in accordance with this disclosure.

As shown in FIG. 12, a biosensor 510 is formed in a manner similar tobiosensor 210 except for the pattern of the conductive material 216positioned on the base 212. In addition to electrode set 268, theconductive material 216 of biosensor 510 defines a first electrode set566. The electrode set 566 is similar to set 366 except for theconfiguration of the interlacing electrode pattern formed by theelements of the electrodes.

Specifically, the first electrode set 566 includes a working electrodehaving an element with one electrode finger 581 and a counter electrodehaving an element with two electrode fingers 580. The fingers 580, 581cooperate with one another to create an interlaced electrode patternconfigured as a macroelectrode array having a feature size or gap widthof about 250 μm. The electrodes 580, 581 each have an electrode width ofabout 250 μm. As discussed above with set 266, the electrode and gapwidths may vary in accordance with this disclosure.

As described above with reference to biosensor 210, the first and secondelectrode sets 566, 268 have different feature sizes and are used tocreate different functionalities on biosensor 510. A non-limitingexample of a suitable functionality of the first electrode set 566 isfor determining correction factors for hematocrit levels. Themeasurement methods are as discussed above with reference to biosensor210.

Referring now to FIG. 13, a biosensor 610 is formed in a manner similarto biosensor 210 except for the pattern of the conductive material 216positioned on the base 212. In addition to the first electrode set 566as discussed above, the conductive material 216 of biosensor 610 definesa second electrode set 668 spaced-apart from set 566.

The electrode set 668 is similar to set 268 except for the pattern ofinterlacing electrode pattern in the element of the electrodes.Specifically, the second electrode set 668 includes a working electrodeand a counter electrode, each having an element with three electrodefingers 661. The fingers 661 cooperate with one another to define aninterlaced electrode pattern configured as a microelectrode array havinga feature size or gap width of about 50 μm, which is less than thefeature size of the electrode pattern of the set 566. The electrodes 661each have an electrode width of about 50 μm. As discussed above with set268, the electrode and gap widths may vary in accordance with thisdisclosure.

In addition, biosensor 610 includes a reagent 664. Reagent 664 issimilar to reagent 264, and only differs in its width as it is appliedonto the base 212. Specifically, the reagent 664 extends acrosselectrode fingers 661. A non-limiting example of a suitablefunctionality of the second electrode set 668 is a glucose determinationfunctionality. The measurement methods are as discussed above withreference to biosensor 210.

As shown in FIG. 14, a biosensor 710 is formed in a manner similar tobiosensor 210 except for the pattern of the conductive material 216positioned on the base 212. The conductive material 216 of biosensor 710defines the first electrode set 366 as discussed above and a secondelectrode set 768. The electrode set 768 is similar to set 268 exceptfor the pattern of an interlacing electrode pattern formed by theelement of the electrodes. Specifically, the second electrode set 768includes a working electrode and a counter electrode, each havingelement with five electrode fingers 770. The fingers 770 cooperate withone another to define an interlaced electrode pattern configured as amicroelectrode array having a feature size or gap width of about 30 μm,which is less than the feature size of electrode pattern of set 366. Theelectrode fingers 770 each have an electrode width of about 50 μm. Asdiscussed above with set 266, the electrode and gap widths may vary inaccordance with this disclosure. A non-limiting example of a suitablefunctionality of the second electrode set 668 is a glucose determinationfunctionality. The measurement methods are as discussed above withreference to biosensor 210.

In addition, biosensor 710 includes a reagent 364 that is dispensed uponthe fingers 770 by any of a variety of dispensing methods that are wellknown to those skilled in the art. Reagent 364 is preferably the reagentset forth in Table 3. Moreover, it is appreciated that a variety ofreagents, non-limiting examples of which have been discussed above, maybe used in accordance with this disclosure.

FIG. 15 illustrates a biosensor 1310 in accordance with this disclosure.Biosensor 1310 is formed in a manner similar to biosensor 210 except forthe configuration of the conductive material 216 positioned on the base212, the cover 1118, and the spacer 1114. The cover 1118 and spacer 1114are similar to cover 218 and spacer 214 except for their dimensionsrelative to the base 212 as shown in FIG. 15. The conductive material216 of biosensor 1310 defines a first electrode set 1366 and a secondelectrode set 1368. The first electrode set 1366 includes a workingelectrode and a counter electrode, each having five electrode fingers1370. The fingers 1370 cooperate with one another to define aninterlaced electrode pattern formed as a microelectrode array having afeature size or gap width of about 17 μm. The electrode fingers 1370each have an electrode width of about 20 μm.

The second electrode set 1368 includes a working electrode and a counterelectrode, each having three electrode fingers 1371. The electrodefingers 1371 cooperate with one another to define an interlacedelectrode pattern formed as a microelectrode array having a feature sizeor gap width of about 10 μm. The electrode fingers 1371 each have anelectrode width of about 20 μm. As discussed above with set 266, theelectrode and gap widths of fingers 1370 and 1371 may vary in accordancewith this disclosure.

The reagent 264 extends across the electrode fingers 1371 of theelectrode set 1368. A non-limiting example of a suitable functionalityof the first electrode set 1366 includes hematocrit correction asdescribed above with reference to biosensor 210. Likewise, anon-limiting example of a suitable functionality of the second electrodeset 1368 is used for determining a glucose estimate as described abovewith reference to biosensor 210. The method of measurement for theelectrode sets, 1366 and 1368 is also as described above with referenceto biosensor 210.

FIG. 16 illustrates biosensor 1510. Biosensor 1510 is identical tobiosensor 210, except for the reagent 1564. Reagent 364 is dispensedonto the electrode fingers 284 as discussed above with reference tobiosensor 710 of FIG. 14.

FIGS. 21-24 are photographs of electrical patterns formed using theprinciples of the present invention. FIG. 21 is a photograph of a basesubstrate having an electrical pattern formed thereon by removing 10% ofthe conductive material initially covering the base substrate. In thisembodiment the conductive material is gold. The pattern was formed witha single pulse of a laser.

FIG. 22 is a photograph of a base substrate having an electrical patternformed thereon by removing 20% of the conductive material initiallycovering the base substrate. In this embodiment the conductive materialis gold and the gap widths are approximately 20 μm as indicated. Thepattern was formed with a single pulse of a laser.

FIG. 23 is a photograph of a base substrate having an electrical patternformed thereon by removing 50% of the conductive material initiallycovering the base substrate. In this embodiment the conductive materialis gold and the gap widths are approximately 20 μm as indicated. Thepattern was formed with a single pulse of a laser.

FIG. 24 is a photograph of a base substrate having an electrical patternformed thereon by removing 90% of the conductive material initiallycovering the base substrate. In this embodiment the conductive materialis gold and the gap widths are approximately 250 μm as indicated. Thepattern was formed with a single pulse of a laser.

Several production runs were made which demonstrate the very fast speedin which the electrical patterns of the biosensors in accordance withthe present invention can be produced. Many of the runs includedelectrode patterns with two different feature sizes, as indicated inTable 4. FIGS. 21-24 are photos taken of selected ones of the electrodestructures, as also indicated in Table 4. The masks used to make thepatterns included both “Structure 1” and “Structure 2” listed in Table4. A single laser pulse of about 25 nanoseconds was used to form thepatterns. As indicated, long webs (about 450 m or more) of material werepassed under the laser ablation apparatus at a controlled speed as theelectrical patterns were formed. The pitch or distance between theelectrical patterns was 9.015 mm for all runs, which corresponds to apreferred width of a biosensor made in accordance with the presentinvention. TABLE 4 Roll Structure 1 Structure 2 Run time Patterns LengthRun # Finger/Gap (μm) Finger/Gap (μm) (min) per min. Figure (m) 1 20/20250/200 20 2585 466 2 250/50  — 40 1256 453 3  20/250 250/20  13 3873 24454 (Structure 1) 4 20/20 250/20  22 2284 453 (Structure 2) 5 50/50100/100 22 2289 454 6 100/50  — 20 2518 454 7 20/20 100/20  23 2363 FIG.23 - 490 Structure 1; FIG. 22 - Structure 2 8  50/100 — 19 2755 472 920/20 50/20 19 2860 490

The “patterns per minute” column reflects the speed at which substratesfor individual biosensors can be formed. For example, in Run No. 1, 2585base substrates each corresponding to a single biosensor, and eachhaving two (2) electrode feature sizes, are formed in a single minute.As can be seen from the above table 4, the method embodied by thepresent invention is well suited to fast mass production.

Although the invention has been described in detail with reference to apreferred embodiment, variations and modifications exist within thescope and spirit of the invention, on as described and defined in thefollowing claims.

1. A biosensor, comprising: a base substrate having first and secondelectrode elements formed thereon; the first and second electrodeelements having first and second respective edges defining a gaptherebetween, the gap having a width and a length; the first edge beingspaced from a first theoretical line by a first distance that variesalong the length of the gap, the first theoretical line defining adesired shape and placement of the first edge, wherein the standarddeviation of the first distance is less than about 6 μm over the entirelength of the gap; a reagent at least partially covering the basesubstrate; and one or more layers overlying and adhered to the basesubstrate, the one or more layers cooperating to form a sample-receivingchamber and a cover for the biosensor, at least a portion of the reagentand an electrode being positioned in the chamber.
 2. The biosensor ofclaim 1, wherein the standard deviation of the first distance is lessthan about 2 μm.
 3. The biosensor of claim 1, wherein the standarddeviation of the first distance is less than about 1 μm.
 4. Thebiosensor of claim 1, wherein the second edge is spaced from a secondtheoretical line by a second distance that varies along the length ofthe gap, the second theoretical line defining a desired shape andplacement of the second edge, wherein the standard deviation of thesecond distance is less than about 6 μm over the entire length of thegap.
 5. The biosensor of claim 4, wherein the standard deviation of boththe first distance and the second distance is less than about 2 μm. 6.The biosensor of claim 4, wherein the standard deviation of both thefirst distance and the second distance is less than about 1 μm.
 7. Thebiosensor of claim 1, wherein the gap width is about 250 μm or less. 8.The biosensor of claim 1, wherein the gap width is less than about 50μm.
 9. The biosensor of claim 1, wherein the gap width is less thanabout 20 μm.
 10. The biosensor of claim 1, wherein the electrodeelements are formed by broad field laser ablation.
 11. The biosensor ofclaim 1, wherein the first and second electrode elements comprise afirst electrode set, one of the electrodes of the set being theelectrode positioned in the sample receiving chamber.
 12. The biosensorof claim 11, further comprising a second electrode set formed on thebase substrate, the second electrode set having a different feature sizethan the first electrode set.
 13. The biosensor of claim 1, wherein thefirst and second electrode elements comprise first and second electrodetraces.
 14. The biosensor of claim 1, wherein the first and secondelectrode elements comprise first and second contact pads.
 15. Thebiosensor of claim 1, wherein the length of the gap is at least 0.1 mm.16. The biosensor of claim 1, wherein the length of the gap is at least1 mm.
 17. The biosensor of claim 1, wherein the length of the gap is atleast 1 cm.
 18. The biosensor of claim 1, wherein the length of the gapis at least one third the length of the biosensor.
 19. The biosensor ofclaim 1, wherein the length of the gap is at least one half the lengthof the biosensor.
 20. The biosensor of claim 1, wherein the gap ispositioned within the sample receiving chamber.
 21. The biosensor ofclaim 1, wherein the electrode elements comprise contact pads and thegap extends between the contact pads.
 22. The biosensor of claim 1,wherein the electrode elements comprise electrode traces and the gapextends between the electrode traces.
 23. The biosensor of claim 1,wherein the electrode elements comprise a working electrode and acounter electrode and the gap extends between the working electrode andthe counter electrode.
 24. The biosensor of claim 23, wherein the gapextends across the sample receiving chamber.
 25. A biosensor,comprising: a base substrate having first and second electrode elementsformed thereon; the first and second electrode elements having first andsecond respective edges defining a gap therebetween, the gap having awidth and a length; the first edge being spaced from a first theoreticalline by a first distance that varies along the length of the gap, thefirst theoretical line defining a desired shape and placement of thefirst edge, wherein the first distance is less than about 6 μm over theentire length of the gap; a reagent at least partially covering the basesubstrate; and one or more layers overlying and adhered to the basesubstrate, the one or more layers cooperating to form a sample-receivingchamber and a cover for the biosensor, at least a portion of the reagentlayer and an electrode being positioned in the chamber.
 26. Thebiosensor of claim 25, wherein the first distance is less than about 2μm.
 27. The biosensor of claim 25, wherein the first distance is lessthan about 1 μm.
 28. The biosensor of claim 25, wherein the second edgeis spaced from a second theoretical line by a second distance thatvaries along the length of the gap, the second theoretical line defininga desired shape and placement of the second edge, wherein the seconddistance is less than about 6 μm over the entire length of the gap. 29.The biosensor of claim 28, wherein the first distance and the seconddistance are both less than about 4 μm.
 30. The biosensor of claim 28,wherein the first distance and the second distance are both less thanabout 2 μm.
 31. The biosensor of claim 25, wherein the electrodeelements are formed by broad field laser ablation.
 32. The biosensor ofclaim 25, wherein the first and second electrode elements comprise anelectrode set, one of the electrodes of the set being the electrodepositioned in the sample receiving chamber.
 33. The biosensor of claim32, further comprising a second electrode set formed on the basesubstrate, the second electrode set having a different feature size thanthe first electrode set.
 34. The biosensor of claim 25, wherein thefirst and second electrode elements comprise first and second electrodetraces.
 35. The biosensor of claim 25, wherein the first and secondelectrode elements comprise first and second contact pads.
 36. A methodof making a biosensor comprising the following steps: providing a basesubstrate having a layer of electrically conductive material thereon;removing a portion of the conductive material to form first and secondelectrode elements on the base substrate having first and secondrespective edges defining a gap therebetween, the gap having a width anda length; the first edge being spaced from a first theoretical line by afirst distance that varies along the length of the gap, the firsttheoretical line defining a desired shape and placement of the firstedge, wherein the standard deviation of the first distance is less thanabout 6 μm over the entire length of the gap; providing a reagent atleast partially covering the base; and adhering one or more layers tothe base, the one or more layers cooperating to form a sample-receivingchamber and a cover for the biosensor, at least a portion of the reagentand an electrode being positioned within the chamber.
 37. The method ofclaim 36, further comprising removing at least 10% of the conductivematerial.
 38. The method of claim 36, further comprising removing atleast 50% of the conductive material.
 39. The method of claim 36,further comprising removing at least 90% of the conductive material. 40.The method of claim 36, wherein the electrically conductive material isremoved by broad field laser ablation.
 41. The method of claim 36,wherein the first and second electrode elements comprise a firstelectrode set.
 42. The method of claim 41, further comprising forming asecond electrode set on the base substrate having a feature sizedifferent from the first electrode set, one of the electrodes of thefirst electrode set being the electrode positioned within the samplereceiving chamber and one of the electrodes of the second electrode setbeing positioned in the sample receiving chamber.
 43. The method ofclaim 36, wherein the standard deviation is less than about 2 μm. 44.The method of claim 36, wherein the standard deviation is less thanabout 1 μm.
 45. The method of claim 36, further comprising forming theelectrode elements in less than about 0.25 seconds.
 46. The method ofclaim 36, further comprising forming the electrode elements in less thanabout 50 nanoseconds.
 47. The method of claim 36, further comprisingforming the electrode elements in less than about 25 nanoseconds. 48.The method of claim 36, wherein the step of adhering the one or morelayers to the base comprises laminating a spacing layer having a voidthat defines the perimeter of the sample receiving chamber over the basesubstrate and laminating a covering layer over the spacing layer. 49.The method of claim 48, further comprising forming a vent opening in thecovering layer that communicates with the sample receiving chamber. 50.A method of forming a biosensor used to measure presence orconcentration of an analyte in a fluid sample, comprising: (a) providingan electrically conductive material on a base; (b) removing a portion ofthe electrically conductive material by broad field laser ablation toform an electrode set on the base; (c) providing a reagent at leastpartially covering the base; and (d) adhering one or more layers to thebase, the one or more layers cooperating to form a sample-receivingchamber and a cover for the biosensor, at least a portion of both thereagent layer and the electrode set being positioned in the chamber. 51.The method of claim 50, wherein the electrode set comprises first andsecond electrodes having first and second respective edges defining agap therebetween, the gap having a width and a length, the first edgebeing spaced from a first theoretical line by a first distance thatvaries along the length of the gap, the first theoretical line defininga desired shape and placement of the first edge, wherein the standarddeviation of the first distance is less than about 6 μm over the entirelength of the gap.
 52. The method of claim 51, wherein the standarddeviation of the first distance is less than about 2 μm.
 53. The methodof claim 51, wherein the standard deviation of the first distance isless than about 1 μm.
 54. The method of claim 51, wherein the electrodeset comprises at least two electrode sets having different featuresizes.
 55. The method of claim 50, wherein the electrode set comprisesat least two electrode sets having different feature sizes.
 56. Themethod of claim 50, wherein step (c) comprises at least partiallycovering the electrode set with the reagent.
 57. The method of claim 50,further comprising removing at least 10% of the conductive material. 58.The method of claim 50, further comprising removing at least 50% of theconductive material.
 59. The method of claim 50, further comprisingremoving at least 90% of the conductive material.
 60. A method offorming a biosensor used to measure concentration of an analyte in afluid sample, comprising: (a) providing an electrically conductivematerial on a base; (b) removing at least 10% of the electricallyconductive material to form at least two electrode sets on the base, theelectrode sets having different feature sizes; (c) providing a reagentat least partially covering the base; and (d) adhering one or morelayers to the base, the one or more layers cooperating to form asample-receiving chamber, at least a portion of one of the electrodesets being positioned in the chamber.
 61. The method of claim 60,further comprising removing at least 50% of the conductive material. 62.The method of claim 60, further comprising removing at least 90% of theconductive material.
 63. The method of claim 60, wherein theelectrically conductive material is removed by broad field laserablation.
 64. The method of claim 60, wherein one of the electrode setscomprises first and second electrodes having first and second respectiveedges defining a gap therebetween, the gap having a width and a length,the first edge being spaced from a first theoretical line by a firstdistance that varies along the length of the gap, the first theoreticalline defining a desired shape and placement of the first edge, whereinthe standard deviation of the first distance is less than about 6 μmover the entire length of the gap.
 65. The method of claim 64, whereinthe standard deviation of the first distance is less than about 2 μm.66. The method of claim 64, wherein the standard deviation of the firstdistance is less than about 1 μm.
 67. The method of claim 60, whereinstep (c) comprises at least partially covering the electrode set withthe reagent.
 68. A method of manufacturing a plurality of biosensors,comprising: (a) providing a web of base substrate material having ametal conductive layer formed thereon; (b) projecting an image of anelectrode pattern onto the metal conductive layer with a laserapparatus, wherein an electrode pattern that corresponds to the image isformed by laser ablation on the web of base substrate material; (c)moving one of the laser apparatus and the web of base substrate materialand repeating step (b) a plurality of times to produce a plurality ofthe electrode patterns at spaced intervals along the web of basesubstrate material; (d) depositing a reagent on the web of basesubstrate material and at least partially covering each electrodepattern of the plurality of electrode patterns with the reagent; (e)laminating at least one web of a covering layer or a spacing layer overthe web of base substrate material, thereby forming a cover and asample-receiving chamber for each biosensor; and (f) cutting through theat least one web of a covering layer or a spacing layer and the web ofbase substrate material to form the plurality of biosensors.
 69. Themethod of claim 68, wherein the electrode pattern formed in step (b)comprises a complete electrode pattern for one of the biosensors,whereby the complete electrode pattern for each biosensor is formed in asingle step.
 70. The method of claim 68, wherein the electrode patternformed in step (b) comprises a partial electrode pattern, the imagecomprises a plurality of the same or different images, and steps (b) and(c) are repeated until the plurality of electrode patterns comprises aplurality of complete electrode patterns, whereby each completeelectrode pattern is formed in multiple steps.
 71. The method of claim68, wherein step (c) comprises continuously moving the web of basesubstrate material.
 72. The method of claim 68, wherein step (c)comprises moving the web of base substrate material in discreteincrements.
 73. The method of claim 68, wherein step (c) comprisesmoving the web of base substrate material at a rate of at least 10meters per minute.
 74. The method of claim 68, wherein the electrodepattern includes at least two electrode sets having different featuresizes.
 75. The method of claim 68, wherein the electrode patterncomprises first and second electrodes having first and second respectiveedges defining a gap therebetween, the gap having a width and a length,the first edge being spaced from a first theoretical line by a firstdistance that varies along the length of the gap, the first theoreticalline defining a desired shape and placement of the first edge, whereinthe standard deviation of the first distance is less than about 6 μmover the entire length of the gap.
 76. The method of claim 75, whereinthe standard deviation is less than about 2 μm.
 77. The method of claim75, wherein the standard deviation is less than about 1 μm.
 78. Themethod of claim 68, wherein the metal conductive layer comprises atleast one member selected form the group consisting of gold, platinum,palladium and iridium.
 79. The method of claim 68, wherein step (e)comprises: laminating the spacing layer over the base substratematerial, the spacing layer having a void that defines the perimeter ofthe chamber; and laminating the covering layer over the spacing layer.80. The method of claim 68, wherein each electrode pattern formed instep (b) is formed in less than 1 second.
 81. The method of claim 68,wherein each electrode pattern formed in step (b) is formed in less than0.25 second.
 82. The method of claim 68, wherein each electrode patternformed in step (b) is formed all at once.
 83. The method of claim 68,wherein each electrode pattern formed in step (b) comprises the entireelectrode pattern for one of the biosensors and each entire electrodepattern is formed all at once.
 84. The method of claim 68, wherein thereagent is applied in a substantially continuous stripe.
 85. The methodof claim 68, wherein the electrode pattern is anisotropic.
 86. Themethod of claim 68, wherein the electrode pattern is asymmetric.
 87. Themethod of claim 68, wherein the electrode pattern formed in step (b)comprises a complete electrode pattern for one of the biosensors,whereby the complete electrode pattern for each biosensor is formed in asingle step, the method further comprising forming the completeelectrical patterns at a rate of at least 100 per minute.
 88. The methodof claim 87, wherein forming the electrode patterns comprises removingat least 20% of the metal conductive layer.
 89. The method of claim 87,wherein forming the electrode patterns comprises removing at least 50%of the metal conductive layer.
 90. The method of claim 87, whereinforming the electrode patterns comprises removing at least 90% of themetal conductive layer.
 91. The method of claim 68, wherein theelectrode pattern formed in step (b) comprises a complete electrodepattern for one of the biosensors, whereby the complete electrodepattern for each biosensor is formed in a single step, the methodfurther comprising forming the complete electrical patterns at a rate ofat least 1000 per minute.
 92. The method of claim 91, wherein formingthe electrode patterns comprises removing at least 20% of the metalconductive layer.
 93. The method of claim 91, wherein forming theelectrode patterns comprises removing at least 50% of the metalconductive layer.
 94. The method of claim 91, wherein forming theelectrode patterns comprises removing at least 90% of the metalconductive layer.
 95. The method of claim 68, wherein the electrodepattern formed in step (b) comprises a complete electrode pattern forone of the biosensors, whereby the complete electrode pattern for eachbiosensor is formed in a single step, the method further comprisingforming the complete electrical patterns at a rate of at least 2000 perminute.
 96. The method of claim 95, wherein forming the electrodepatterns comprises removing at least 20% of the metal conductive layer.97. The method of claim 95, wherein forming the electrode patternscomprises removing at least 50% of the metal conductive layer.
 98. Themethod of claim 95, wherein forming the electrode patterns comprisesremoving at least 90% of the metal conductive layer.
 99. The method ofclaim 68, wherein the electrode pattern formed in step (b) comprises acomplete electrode pattern for one of the biosensors, whereby thecomplete electrode pattern for each biosensor is formed in a singlestep, the method further comprising forming the complete electricalpatterns at a rate of at least 3000 per minute.
 100. The method of claim99, wherein forming the electrode patterns comprises removing at least20% of the metal conductive layer.
 101. The method of claim 99, whereinforming the electrode patterns comprises removing at least 50% of themetal conductive layer.
 102. The method of claim 99, wherein forming theelectrode patterns comprises removing at least 90% of the metalconductive layer.